Generator Welder

8/10/2019 Generator Welder

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OWNERS MANUAL

AIR-COOLED DIESEL ENGINE GENERATOR WELDER SET

DWG6LE / DWG6LN

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PREFACE

Thank you for purchasing products from EASTERN TOOLS & EQUIPMENT, INC. We

appreciate your business. The following manual is only a guide to assist you and is not a

complete or comprehensive manual of all aspects of maintaining and repairing your

generator/welder. The equipment you have purchased is a complex piece of machinery.We recommend that that you consult with a dealer if you have doubts or concerns as to

your experience or ability to properly maintain or repair your equipment. You will savetime and the inconvenience of having to go back to the store if you choose to write or call

us concerning missing parts, service questions, operating advice, and/or assembly

questions. Our air-cooled diesel welders and generators have some of the following

features:

Lightweight construction

Air cooled

Four-stroke diesel internal combustion engine

Direct fuel injection system Recoil starter or an optional electric starter

Large fuel tank

Automatic voltage stabilizer

NFB circuit protector

AC and DC outputs

Low oil pressure sensor

The ETQ air-cooled diesel welder and generator set are widely used when electrical

power is scarce. Our welders provide a portable mobile solution in supplying power andfabrication needs for field operations during project construction. Some other known

applications include pipeline construction and metal welding when electrical power is notavailable.

This manual will explain how to operate and service your welder and generator set.

If you have any questions or suggestions about this manual, please contact your local

dealer or us directly. Consumers should notice that this manual might differ slightly

from the actual product as more improvements are made to our products. Some of the

pictures in this manual may differ slightly from the actual product as well.

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TABLE OF CONTENTS

Page numberOverall view of the generator and welder set 4

Chapter 1 Technical Specifications and Data 51-1 Technical specifications and data 51-2 Basic operating parameters 7

1-3 General dimensions and overview of the generators and welders 7

1-4 Electric wiring diagrams for various models of generators 8

Chapter 2 Operating the Diesel Generator 11

2-1 Main points of safety during operation of the welder generator 11

2-2 Preparation before operation 132-3 Checking the operation of the diesel engine 16

2-4 Starting the welder and generator set 16

2-5 Procedures for starting the welder generator set 192-6 Proper operation of the welder generator set 212-7 Loading 21

2-8 Stopping the generator 24

Chapter 3 Maintenance 25

3-1 Maintenance schedules 25

3-2 Storing for long periods of time 26

Chapter 4 Overhauling and Troubleshooting 28

4-1 Overhauling and troubleshooting procedures 28

4-2 Questions and doubts 28

Chapter 5 Generator Parts Diagrams and Listings 29

Limited Warranty 33Product Registration Card 34

List for comments from users 36Appendix 36

1. Attached list of tools fittings, and subassemblies 36

2. Attached technical documents 36

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1. Overall view of the DWG6LE series 3. Overall view of the DWG6LE-B series

2. Overall view of the DWG6LE-A 4. Overall view of the DWG6LN series


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CHAPTER 1. TECHNICAL SPECIFICATIONS AND DATA

1-1 Technical specifications and data (in SI units)

Item Model DWG6LE DWG6LN

Frequency (Hz) 60 60

Rated power (kW) 2.7 2.7

Voltage (AC) (V) 120 / 240 120 / 240

Current (AC) (A) 11 11

Quantity of phase Single-phase

Generator

Technical

Data

(AC)

Power factor (cos ) 1.0

Electric welding voltage in idle

(DC) (V)

55~65

Rated current for electricwelding (DC) (A)

160~180

Working voltage for electric

welding (DC) (V)

25-30

Electric welding load lasting

rate

50%

Electric

Welding

TechnicalData

(DC)

Current range of electricwelding (A)

80~210

Speed (rpm) 3600 3600

Excitation Governable excitation

Continuous operation time (Hr. by half

load)

Continuous run for 12 hours

Frame type Open frame steel handcart

Connection Rigid connection driven shaftDry weight (kg) 137 181

Electricweldinggeneratordata

Dimensions (LxWxH) (mm) 720x480x645 910x520x740

Engine Type ETQ186FG

Continuous (kW) 6.6 6.6Output

Maximum (kW) 7.35 7.35

Bore x Stroke (mm) 86 x 70

Displacement (cc) 406

Lube-oil capacity (L) 1.65

Fuel tank capacity (L) 15

Lubricating system Pressure splash, duplex type

lubrication

Starting system Recoil manual start / Electric Start

Eng

ine

Cooling system Forced air cooling by flywheel fan


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Technical specifications in English units

Item M DWG6LE DWG6LN

Frequency (Hz) 60 60

Rated power (HP) 3.6 3.6

Voltage (AC) (V) 120 / 240 120 / 240Current (AC) (A) 11 11

Quantity of phase Single-phase

Generator

Technical

Data

(AC)

Power factor (cos ) 1.0

Electric welding voltage in

idle (DC) (V)

55~65

Rated current for electric

welding (DC) (A)

160~180

Working voltage for electric

welding (DC) (V)

25-30

Electric welding load lasting

rate

50%

Electric

Welding

TechnicalData

(DC)

Current range of electric

welding (A)

80~210

Speed (rpm) 3600 3600

Excitation Governable excitation

Continuous operation time (Hr. by halfload)

Continuous run for 12 hours

Frame type Open frame steel handcart

Connection Rigid connection driven shaft

Dry weight (lbs) 304 400

Electricweldinggeneratordata

Dimensions (LxWxH) (in) 28.35x18.9x25.39 35.82x20.47x29.13

Engine Type ETQ186FG

Continuous (HP) 8.85 8.85Output

Maximum (HP) 9.85 9.85

Bore x Stroke (in) 3.39 x 2.76

Displacement (cu. in) 24.8

Lube-oil capacity (oz) 55.75

Fuel tank capacity (US gal) 3.96

Lubricating system Pressure splash, duplex type

lubrication

Starting system Recoil manual start / Electric Start

Engine

Cooling system Forced air cooling by flywheel fan


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1-2 Basic operating parameters

1-2.1 Under the given conditions, the generator will output the specified power in the

table listed below.Table 1.

Height above sea level (ft) Ambient temperature (o

F) RH0 +60 (+20

oC) 60%


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1-4 Electric wiring diagrams for diesel welder generators


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CHAPTER 2 OPERATING THE DIESEL GENERATOR

2-1 General main points of safety during operation of the welder and generator set.

In order to operate the welder and generator set safely, please follow all the instructions

provided in this manual carefully. Doing so otherwise may lead to accidents and orequipment damage.

2-1.1 Fire prevention

The proper fuel for the diesel generator set is light diesel fuel. Do not use gasoline,

kerosene and or other fuels other than light diesel fuel. Keep all flammable fuels away

from the generator as the generator may spark and ignite these gases. In order to preventfires from occurring and to provide enough ventilation for people and the machine, keep

the diesel generator at least 1.5 meters away from buildings and or other equipment.

Always operate your diesel generator on a level site. If the generator is operated on an

incline, the lubricating system within the engine will not perform well and may lead tofailure of the engine.

2-1.2 Prevention from inhaling exhaust gases

Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic

carbon monoxide. Never operate your generator in places with poor ventilation. In orderto operate this machinery indoors, a suitable ventilation system for the building is

required to draw the poisonous exhaust gases out.

2-1.3 Prevention from accidental burns

Never touch the muffler and its cover when the diesel engine is running. Never touch themuffler and cover after the diesel engine has been used, as the muffler remains hot for a

good period of time.

2-1.4 Electric shock and short circuits

Never touch the generator if the generator is wet. Also never touch the generator if your

hand is wet. Never operate your generator if the weather conditions call for any type ofprecipitation such as rain, snow, or fog. To prevent electrical shocks, the generator

should be grounded. Use a lead to connect the grounding end of the generator to the

grounding surface of choice. Please refer to Fig. 2-1 and Fig. 2-2 before beginning to usethe electric welding generator.


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Fig 2-1 Fig 2-2

Note: When connecting devices to the generator,

make sure all other devices are rated lower than

the generators output. Any generator socketshould not be overloaded over its regulated limit

2-1.5 Other safety points

Before operating this generator, all operators should have a good knowledge of how to

break the circuit if any accidents occur. Also, all operators should be familiar with all theswitches and functions of the generator before using this machine. While operating the

generator, wear safe shoes and suitable clothes during operation. Always keep children

and animals away from the generator.

2-1.6 Battery

The electrolytic liquid of the battery contains sulfuric acid. In order to protect your eyes,

skin, and clothing, wear protective gear when working with the battery. If you come in

contact with the electrolytic liquid, wash it immediately with clean water. Also, if the

electrolytic liquid comes in contact with your eyes, see a doctor immediately.


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2-2 Preparation before operation

2-2.1 Fuel choices and fuel treatment

Air filter element

Do not wash the air filter. Theelement is made of dry material,

which does not permit washing.

When the output of the dieselengine is bad or the color of the

exhaust gas is abnormal, replace the

air filter element. Never start the

diesel engine without the air filter.

Fuel tank

Use only light diesel fuel. The fuel

should be filtered clean. Never letdust and water mix with fuel in thefuel tank. Otherwise it will clog the

fuel lines and oil nozzles. It may also

damage your pressure pump.

Note: It is dangerous to overfill thefuel tank. Never exceed the red piston

in the filter.

a. After purchasing fuel, put it

into a drum and let it sit for 3-4 days.

b. 3-4 days later, insert half ofthe fuel sucker into the drum,

(water and impurities stay inthe lower portion of the

drum)

Note:Never smoke near the opening of

the fuel tank. Do not let sparks get

near the fuel or fuel tank and do notoverfill tank. After filling, tighten

the fuel cap.


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2-2.2 Filling engine oil

Remove the dipstick from the engine

Make sure the generator is on levelground, and fill the engine with 15W40

engine oil. Put the dipstick back into thehole to check the engine oil level.

Engine oil is the most important factor in determining the life of your generator engine.

If you use poor engine oil or if you dont change the oil regularly, the piston and cylinderwill wear easily or seize up. Also, the life of the other parts in your engine such as

bearings, and other rotating parts will shorten considerably.

Although there is an alarm system to check for low oil pressure, it is always a good ideato check the amount of oil inside the engine. If the oil level is low, fill it before starting

the engine. A good time to drain the oil from the engine is when the diesel engine is still

hot. If the engine is fully cooled, it is more difficult to drain all the oil out or someimpurities will remain in the engine.


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2-2.3 Checking the air filter

(1) Loosen the butterfly nut, take thecover of the air filter off and take

the air filter element out.

Do not use detergent to wash the air

filter element. When the

performance of the engine decreasesor when the color of the exhaust

gases is bad, exchange the filter

element. Never start the enginewithout the air filter as foreign

objects may enter the intake and

damage the engine.

(2) After replacing the air filter

element, replace the cover and

tighten the butterfly nut firmly.

2-2.4 Checking the generator welder

Butterfly nut (Note: Only certain welder generator setshave an electric fan incorporated on them.)

Before starting the generator, make

sure the air switch is in the Off

position. Starting the generator with

the switch in the On switch is verydangerous.

The generator should be grounded inorder to prevent electric shock.

Use dry compressed air (withpressure about 1.96 x 105 Pa) to

blow the dust out in the electric

control cabinet and at the surface ofthe generator. Check to see how

clean the surface of the sliding ringis. Check the pressure of the carbon

brush. Also, check whether theposition of the carbon brush at the

slide rig is correct and the fixture isreliable with a good contact.

According to the electric wiringdiagram, check to see whether the

connecting wire is correct and the

connected place is firm.

Use a 500 M meter to measure the

insulation resistance of the electricalpart. The resistance should be no

less than 5M . When measuringdevices, make sure the AVR is

turned off. Otherwise, it will burn

the AVR. (For the low noise set, theinspection may not be performed).


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2-2.5 The fuel and oil in a new

engine is drained before sold.

Before you start the engine, please

fill the fuel tank and engine oil first.Then, check to see if there are air

bubbles in the engine. If there are,follow these procedures. Loosen theconnecting nut between the oil

injection pump and oil pipe. Bleed

the air from the system until thereare no more bubbles. Then replace

the connecting nut and tighten it.

2-3 Checking the operation of the

diesel engine

2-3.1 Low-pressure alarm system.ETQ diesel engines have a low-

pressure sensor system where if

the oil pressure drops too low,the sensor will shut the engine

off. The purpose of having this

system is to ensure that theengine does not seize up. If there

is not enough oil in the engine,

the temperature of the oil will be

raised too high. On the contrary,

if there is too much oil in theengine, the engine oil can slow

the engine down considerably.

2-3.2 How to open the case door/cover

(1) Open the case door: turn the

handle counterclockwise and

open the door. Do thesechecks daily.

(2) Loosen the outer cover bolt

of the air filter and outer

cover of the oil nozzle, andthen check the air filter.

(3) Check the outer cover of the

oil nozzle. Loosen the

butterfly nut and open the

outer cover.

2-3.3 Engine break in

When you purchase a brand new

engine, the engine must beproperly broken in. The break in

period is about 20 hours.

(1) Avoid overloading theengine when brand new

(2) Change the engine oil

according to specifications.An oil change for a brand

new engine is about 20 hours

or every month, an olderengine, the oil change is

about 100 hours or three

months.

2-4 Starting the welder generator set

2-4.1 Manual starting.

Start the engine in accordance withprocedures below:

(1) Put the fuel switch in theOn position.

Knob handle


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(2) Turn the handle of the

engine to the RUN

position.

1. Insert key into ignition and

put it in the off position.

2. Put the speed handle in theRun position.

3. Turn the start switchclockwise to the STARTposition; (to set the silent

type, first turn it clockwise to

the RUN (ON) position for1-2 seconds. The

electromagnetic iron will be

triggered, now turn itclockwise to the START

position.

(3) Pull the recoil starter handleout until you feel resistance.

It will reset to its original

position automatically. Thehandle should be reset into

its recoil device slowly to

prolong the life of the engine

starter.

4. After the diesel engine is

started, remove your handfrom the switch handle; the

switch will automatically

reset itself to the ONposition.

(4) In cold climate, it is difficult

to start the engine. Toremedy this, pull the rubber

plug out from the rocker of

the diesel engine and fill 2ml of engine oil. Before

starting, put the rubber plug

back in place. If you dont

put the rubber plug back in

place, rain, dust and otherdirt can enter into the diesel

engine. It will cause theparts inside the diesel engine

to wear quickly and lead to

engine failure.

2-4.2 Electric starting

The procedures for preparing to start the

engine are the same as the manualstarting engine.

5. If the engine is not starting

after 10 seconds of cranking,wait about 15 seconds before

trying it again. If you crank

to long, the voltage of the

battery will drop. This can

lead to improper ignition.When the diesel engine is

operating, let the ignitionretain on the ON position.

Note:If you crank the starter to long, the

battery may be drained too much to

provide enough energy for proper

engine ignition. Also, when the diesel

engine is operating, let the key retain

in the ON position.


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2-4.3 Battery

Important Notice: All of our units come with a dry battery for shipping safety purposes.

In order to get your generator started for the first time; the battery must be filled withbattery acid which can be purchased at a local automotive supply store and slowly

charged (trickle charged) for a day. After charging, the battery may be used. To properlymaintain your battery; check the height of the battery acid once a month. If the level ofthe liquid drops too low, fill it with distilled water until it reaches the high mark. If there

is not enough battery acid, then the diesel engine cannot be started. It is important to

keep the liquid level between the high and low limits.

If the level in the battery is to high, the liquid may flow out and end up on surrounding

parts resulting in corrosion of these parts.

Note: Avoid too much or too little of battery acid. Check and fill it once a month if

necessary.


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2-5 Procedures for starting the welder generator set

This procedure applies to the L series recoil starting style models.


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2-6 Proper operation of the welder

generator set

2-6.1 Operating the diesel engine

1. Pre-heat the diesel engine for3 minutes under no load

conditions.2. First check the height of the

lubricating oil level, if it is

low, refill it. Our diesel

engines are equipped with analarm system that will notify

you if the oil pressure is too

low. The alarm system willshut down the engine if the

oil pressure is too low.

3. Do not adjust the speed limit

regulation bolt or the fueladjustment bolt. These bolts

have been set by the factory

already, changing them willaffect the properties of the

engine

performance.

2-6.2 Checks during engine operation

1. Check to see if there are

abnormal noises.2. Check to see if the

performance is good or bad3. Check the color of the

exhaust gases (whether it is

too black or too white). If

any of these conditions exist,stop the engine and find the

cause of the problem. If no

problems are found, pleasecontact your local dealer or

our nearest company branch.

2-7 Loading2-7.1 Load conditions

Exert loads in accordance with

the specified parameters. For anelectric schematic of the welder

and generator, please refer to the

following one:

Speed limit boltFuel adjustment bolt

2-7.2 Output of electricity

1. Raise the revolutions per

minute (turn the speed handle

to the max setting) of thegenerator to get the

maximum power out of the

generator. If not, theautomatic voltage regulator

device will excite and doing

this for long periods of timewill cause the AVR to burn.

Fuel adjustment bolt

High-pressure

fuel pipe nut Fuel adjustment

bolt


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For the rated speed of the

generator, please refer to

Chapter 1, item 1-1 technical

specification and data.2. Observe the pointer of the

voltmeter, it should point to230 V 5% (50Hz). (For 60Hz set, it will be 240 V

5%). Meanwhile put the

switch in the GEN(generator) position. The AC

voltage from the socket of the

power supply can be output.3. When connecting devices to

the generator, make sure to

connect these devices in

order. Connect the largeloads onto the generator first.

If everything is functional,

smaller loads can then beadded. If the generator shuts

off, it may be because the

load being drawn by all thevarious devices are too high.

In this event, decrease the

number of small devices until

everything is functional. The

total drawn power should notexceed the maximum output

power of the generator.Please see Table 1-1 for

technical specifications of

what the generator canoutput. In order to reset the

generator after overdrawn

power, let it sit for severalminutes. If the indication of

the voltmeter is too high or

too low, adjust the speedaccordingly. If there areproblems, stop the generator

immediately and fix the

issue.4. Switching the switch to GEN

outputs electrical power.When doing this, there is

enough power for electric

welding, but the output

current is very small. It can

be used for electric weldingrods below 3.2mm only.

The welder of choice shouldbe below 130A. Whenelectric welding, the load at

the output terminal should

not be more than 1 kW. Inorder to guarantee the total

load of the set, a general idea

is (welder load + generatorload).

5. When choosing the WELD

(electric welding), the

generator welder will outputthe necessary power for

welding (the socket of the

generator has no voltageoutput). The desired current

for various electric welding

rods and work can beadjusted through the

potentiometer button on the

switchboard. After adjusting

this to a suitable position, the

welding can be carried out.If a smaller current is desired,

it can be adjusted bydecreasing the speed of the

generator. The maximum

welding current is 210-220A. The maximum current

cannot be used for long

periods of time.6. Before operating the

generator welder set, the

connection between theelectric welding cable andterminal should be tight and

secure to avoid damaging the

terminal caused by a badcontact surface.

7. During operation, thegenerator welder should be in


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a place that has very good

ventilation. Never cover the

engine to solve a ventilation

problem, as this will damageyour equipment.

8. When the generator welder isused for generating electricitypurposes only, the electric

welding cable should be

disconnected. If the purposeis for electric welding

independently, the air switch

should be turned off or

disconnected to avoid a short

circuit at the output end.

9. A reference for variousdevices and the power

required will be provided inTable 2-1. Also a table forvarious diameters of welding

rods versus how much

current is required will beprovided in Table 2-2.

Table 2-1.

Table 2-2.

Note: Do not start more than two devices simultaneously. Each device should be

started one by one to prevent overloading the generator.

In generator should be running at 3600 revolutions per minute in order to achievethe (60 Hz) frequency. The speed of the engine can be adjusted from the speed

governor.

2-7.3 Charging the battery

1. For the electric starter on the generator welder, the 12V battery is

automatically charged through the regulator on the side of the engine when it

is running.2. If the generator is not used for long periods of time, the battery should be

disconnected to avoid energy loss from the battery.

3. Do not connect the negative and positive terminals of the battery together atany time. Doing so will damage the battery and cause serious injuries.

4. Do not reverse the polarities when attaching the battery cables to the battery.

Doing so will damage both the battery and the electric starter.


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5. When charging the battery, the battery produces flammable gases. Do not

smoke, let flames, and sparks get near the battery while it is charging as this

may cause a fire. To avoid sparking while connecting the cables to the

battery, first, connect the cables to the battery then to the motor. Todisconnect battery cables, first disconnect the motor end of the cable.

2-8 Stopping the generator

1. Take the electrical load off

the generator.2. Turn welder generator air

switch off

3. Put the speed handle in theRUN position and let the

engine run for 3 minutes after

unloading. Do not stop the

diesel engine immediately letit warm down. Stopping the

diesel engine suddenly may

raise the temperature of theengine abnormally and lock

the nozzle and damage the

diesel engine.

4. Press down on the brake

handle5. If equipped with an electric

starter, turn the key to the

Off position6. Put the fuel handle to the S

position

7. Finally, pull slowly on the

recoil handle until you feelresistance (this is when the

piston is on the compression

stroke, where the intake andexhaust valves are closed).

What this does is prevent the

engine from rusting when notin use.

Speed handle

Note:

1. If the speed handle is in the

Stop position and the

engine is still running, turnthe fuel switch to the OFF

position or loosen the high

pressure oil pipe nut. The

engine could be stoppedmore than one-way other

than the speed handle way.2. If you cannot stop the

engine with a load on it,

then remove the load first

than stop the engine.


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CHAPTER 3 MAINTENANCE

3-1 Maintenance schedules

Keeping your generator well maintained will prolong the life of your generator.

Everything needs to be checked including the diesel engine, welder, generator, controlcabinet, and frame. For overhauling procedures, please refer to the instruction manual of

the relative subassembly. If you need these manuals, please call our company and wewill send you one.

Before starting the maintenance, make sure the diesel engine is off.

Please refer to the Table 3-1 for the proper maintenance schedule.

Table 3-1. Maintenance schedule for diesel welder generator set


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3-1.1 Changing the engine oil (every

100 hours)

Take the oil cover off. Remove the oildrain plug when the diesel engine is still

hot. Be careful of hot oil and hot engineas you may get burned. The bolt islocated at the bottom of the cylinder.

After draining the oil, put the bolt back

and tighten it. Then fill with the properengine oil to the proper level.

3-1.2 Air filter maintenance schedule

1. Clean air-filter every 6months or 500 hours of

operation.

2. If necessary, exchange it.

3. Do not use detergent to cleanair filter element.

3-1.3 Fuel filter maintenance

1. The fuel filter should be cleaned

often to keep the engine runningat maximum performance.

2. The recommended time periodfor cleaning the fuel filter is 6months or 500 hours of

operation.

a. To do this, first drain thefuel from the fuel tank.

b. Loosen the small screws

on the fuel switch andremove the fuel filter

form the port. Use diesel

fuel to clean the fuel

filter. Also, remove thefuel injector and clean the

carbon deposit around it.

The recommended timeperiod for this is 3

months or 100 hours.

Di stick

High-pressure

fuel pipe bolt

Oil drain bolt

3-1.4 Cylinder head bolt tensions

The cylinder head bolts should be

tightened to specifications please refer to

the diesel engine manual for

specifications and the special toolsrequired to do this.

3-1.5 Battery check

Make sure the electrolytic solution of thebattery is full. The engine uses a 12V

battery. Due to numerous starting

cycles, the electrolytic solution may beused up. Also, before filling, verify that

the battery is not damaged in any way.

Add distilled water to the battery whenfilling. Perform checks on the batteryonce a month.

Note:

Never start the engine withoutthe air filter. This can cause

serious damage to the engine if

foreign objects enter the intake

system. Always change the air

filter on time.


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3-2 Storing for long periods of time

If your generator needs to be stored for long periods of time, the following preparations

should be made.

1. Start the diesel engine for 3 minutes then stop it.2. When the engine is still hot, change the engine oil with new engine oil of the

proper grade.

3. Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating oil

in it, then cover the plughole up again.4. For manual starting generator welders, press the decompression handle down and

pull the recoil handle 2 or 3 times. This pushes the intake out. (Do not start the

engine)5. For electric started generator welders, press the decompression handle down and

crank the engine for 2-3 seconds. To do this, put the starter switch in the Start

position. (Do not start the diesel engine)

6. Finally, pull the recoil starter until you feel resistance; this is when the piston ison the compression stroke where the intake and exhaust valves are closed.

Having the intake and exhaust valves closed will prevent rust, as moisture cannot

get inside the combustion chamber.7. Clean the engine and store it in a dry place.


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CHAPTER 4 OVERHAULING AND TROUBLESHOOTING

4-1 Overhauling and troubleshooting procedures

If you are still having trouble, please contact with your nearest dealer or with our

company directly if necessary.

4-2 Questions and doubts

If you do not understand anything or have any questions, please feel free to contact yourlocal dealer or with our company directly. Below is a list of some information you

should have ready before contacting your local dealer or us.

1. Model of diesel engine generator and engine model number.2. State of residency

3. Number of hours of operating equipment along with the problem that occurred.

4. A detailed condition and time when the problem occurred, in other words, climateand atmosphere


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CHAPTER 5 GENERATOR PARTS DIAGRAMS AND LISTINGS

Figure 5-1. Overall view of generator/welder

Table 5-1. Please refer to figure 5-1 for illustrationNumber Part Description Quantity Part Number (DWG6LE\DWG6LN)

1 ETQ series diesel engine 1 ETQ6DWGLE1 \ ETQ6DWGLN1

2 Starter Motor 1 ETQ6DWGLE2 \ ETQ6DWGLN2

3 Flywheel generator 1 ETQ6DWGLE3 \ ETQ6DWGLN34 Bolt 2 ETQ6DWGLE4 \ ETQ6DWGLN4

5 Voltage Regulator 1 ETQ6DWGLE5 \ ETQ6DWGLN5

6 Battery Cable (red) 1 ETQ6DWGLE6 \ ETQ6DWGLN6

7 Battery Cable (black) 1 ETQ6DWGLE7 \ ETQ6DWGLN7

8 Battery 1 ETQ6DWGLE8 \ ETQ6DWGLN89 Oil level sensor 1 ETQ6DWGLE9 \ ETQ6DWGLN9

10 Output panel assembly 1 ETQ6DWGLE10 \ ETQ6DWGLN10

11 Throttle cable 2 ETQ6DWGLE11 \ ETQ6DWGLN11

12 Connector assembly 1 ETQ6DWGLE12 \ ETQ6DWGLN1213 Capacitor 1 ETQ6DWGLE13 \ ETQ6DWGLN13

14 Bolt 2 ETQ6DWGLE14 \ ETQ6DWGLN14

15 Voltage Regulator Bracket 1 ETQ6DWGLE15 \ ETQ6DWGLN1516 Bolt 2 ETQ6DWGLE16 \ ETQ6DWGLN16


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Figure 5-2. Framework exploded view


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Table 5-2. Please refer to figure 5-2.Number Part Description Quantity Part Number (DWG6LE\DWG6LN N)

1 M6 x 25 Bolt 4 ETQ6DWGLE17 \ ETQ6DWGLN17

2 M6 Flat washer 4 ETQ6DWGLE18 \ ETQ6DWGLN18

3 Shock absorber 4 ETQ6DWGLE19 \ ETQ6DWGLN19

4 Washer 4 ETQ6DWGLE20 \ ETQ6DWGLN20

5 M6 Nut 4 ETQ6DWGLE21 \ ETQ6DWGLN216 Engine cover 1 ETQ6DWGLE22 \ ETQ6DWGLN22

7 Rubber cover 1 ETQ6DWGLE23 \ ETQ6DWGLN23

8 Handrail 1 ETQ6DWGLE24 \ ETQ6DWGLN249 M8 x 65 Bolt 4 ETQ6DWGLE25 \ ETQ6DWGLN25

10 Plastic gasket 4 ETQ6DWGLE26 \ ETQ6DWGLN26

11 Flat washer M8 4 ETQ6DWGLE27 \ ETQ6DWGLN27

12 Spring washer 4 ETQ6DWGLE28 \ ETQ6DWGLN2813 M8 Nut 4 ETQ6DWGLE29 \ ETQ6DWGLN29

14 Battery tie down 1 ETQ6DWGLE30 \ ETQ6DWGLN30

15 M6 Nut 2 ETQ6DWGLE31 \ ETQ6DWGLN31

16 Tie down hooks 2 ETQ6DWGLE32 \ ETQ6DWGLN3217 Battery 1 ETQ6DWGLE33 \ ETQ6DWGLN33

18 M8x12 bolts 2 ETQ6DWGLE34 \ ETQ6DWGLN3419 Rubber absorber 1 ETQ6DWGLE35 \ ETQ6DWGLN3520 Motor mount 1 ETQ6DWGLE36 \ ETQ6DWGLN36

21 Battery tray 1 ETQ6DWGLE37 \ ETQ6DWGLN37


23 Spring washer 6 1 ETQ6DWGLE39 \ ETQ6DWGLN3924 M6 x 35 Bolt 1 ETQ6DWGLE40 \ ETQ6DWGLN40


26 Spring washer 10 2 ETQ6DWGLE42 \ ETQ6DWGLN42

27 Flat washer 10 2 ETQ6DWGLE43 \ ETQ6DWGLN43

28 M10 x 20 2 ETQ6DWGLE44 \ ETQ6DWGLN4429 Bracket 1 ETQ6DWGLE45 \ ETQ6DWGLN45

30 M10 Nut 4 ETQ6DWGLE46 \ ETQ6DWGLN4631 Spring washer 10 4 ETQ6DWGLE47 \ ETQ6DWGLN47

32 Flat washer 10 4 ETQ6DWGLE48 \ ETQ6DWGLN4833 Rubber mounts 4 ETQ6DWGLE49 \ ETQ6DWGLN49

34 Flat washer 10 4 ETQ6DWGLE50 \ ETQ6DWGLN50

35 Spring washer 10 4 ETQ6DWGLE51 \ ETQ6DWGLN5136 M10 Nut 4 ETQ6DWGLE52 \ ETQ6DWGLN52

37 Axle 1 ETQ6DWGLE53 \ ETQ6DWGLN53


39 U bolt 2 ETQ6DWGLE55 \ ETQ6DWGLN5540 Flat washer 20 2 ETQ6DWGLE56 \ ETQ6DWGLN56

41 Split pin 32 x 32 2 ETQ6DWGLE57 \ ETQ6DWGLN57

42 Wheel 2 ETQ6DWGLE58 \ ETQ6DWGLN5843 Solenoid cable bolts 2 ETQ6DWGLE59 \ ETQ6DWGLN59

44 Solenoid 1 ETQ6DWGLE60 \ ETQ6DWGLN60

45 Solenoid bracket 1 ETQ6DWGLE61 \ ETQ6DWGLN6146 Bolts 4 ETQ6DWGLE62 \ ETQ6DWGLN62

47 Throttle cable 1 ETQ6DWGLE63 \ ETQ6DWGLN6348 M8 x 40 Bolt 4 ETQ6DWGLE64 \ ETQ6DWGLN64


50 Bracket 2 ETQ6DWGLE66 \ ETQ6DWGLN6651 Bracket 1 ETQ6DWGLE67 \ ETQ6DWGLN67

52 Rubber insulator 2 ETQ6DWGLE68 \ ETQ6DWGLN68


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Figure 5-3.Electric panel parts drawing

Table 5-3. Please refer to Figure 5-3Number Part Description Quantity Part Number (DWG6LE\DWG6LN)

1 Positive DC port 1 ETQ6DWGLE69 \ ETQ6DWGLN69

2 Negative DC port 1 ETQ6DWGLE70 \ ETQ6DWGLN703 Grounded bolt 1 ETQDWGLE71 \ ETQ6DWGLN71


5 Large Nut 1 ETQ6DWGLE73 \ ETQ6DWGLN736 Bolt 2 ETQ6DWGLE74 \ ETQ6DWGLN74


8 Large Nut 1 ETQ6DWGLE76 \ ETQ6DWGLN769 Current Adjusting Switch 1 ETQ6DWGLE77 \ ETQ6DWGLN77

10 3 prong Socket 2 ETQ6DWGLE78 \ ETQ6DWGLN7811 Bolt 6 ETQ6DWGLE79 \ ETQ6DWGLN79

12 Electric panel bolt 6 ETQ6DWGLE80 \ ETQ6DWGLN80

13 Electric Panel 1 ETQ6DWGLE81 \ ETQ6DWGLN8114 Starter switch 1 ETQ6DWGLE82 \ ETQ6DWGLN82

15 Large nut 6 ETQ6DWGLE83 \ ETQ6DWGLN83

16 Oil alert lamp 1 ETQ6DWGLE84 \ ETQ6DWGLN84

17 Hour meter 1 ETQ6DWGLE85 \ ETQ6DWGLN8518 Hour meter bolts 2 ETQ6DWGLE86 \ ETQ6DWGLN86

19 DC Fuse 1 ETQ6DWGLE87 \ ETQ6DWGLN87

20 Voltmeter 1 ETQ6DWGLE88 \ ETQ6DWGLN88

21 Nut 2 ETQ6DWGLE89 \ ETQ6DWGLN8922 4 prong socket 1 ETQ6DWGLE90 \ ETQ6DWGLN9023 Breaker bracket 1 ETQ6DWGLE91 \ ETQ6DWGLN91

24 Nut 2 ETQ6DWGLE92 \ ETQ6DWGLN92

25 Breaker 1 ETQ6DWGLE93 \ ETQ6DWGLN9326 Wiring harness 1 ETQ6DWGLE94 \ ETQ6DWGLN94

27 Electrical box 1 ETQ6DWGLE95 \ ETQ6DWGLN95


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Figure 5-4. Generator head assembly

Table 5-4. Please refer to figure 5-4Number Part Description Quantity Part Number (DWG6LE\DWG6LN)

1 Front end cover 1 ETQ6DWGLE96 \ ETQ6DWGLN962 Diode 2 ETQ6DWGLE97 \ ETQ6DWGLN97

3 M4 x 8 Bolt 2 ETQ6DWGLE98 \ ETQ6DWGLN98

4 Fan Blade 1 ETQ6DWGLE99 \ ETQ6DWGLN995 Bearing 1 ETQ6DWGLE100 \ ETQ6DWGLN100

6 Rotor Unit 1 ETQ6DWGLE101 \ ETQ6DWGLN101

7 Center bolt 1 ETQ6DWGLE102 \ ETQ6DWGLN102

8 Motor cover 1 ETQ6DWGLE103 \ ETQ6DWGLN1039 Stator 1 ETQ6DWGLE104 \ ETQ6DWGLN104

10 Long bolt 4 ETQ6DWGLE105 \ ETQ6DWGLN105

11 Capacitor 1 ETQ6DWGLE106 \ ETQ6DWGLN106

12 Wiring Seat 1 ETQ6DWGLE107 \ ETQ6DWGLN10713 M5 x 15 Bolt 6 ETQ6DWGLE108 \ ETQ6DWGLN10814 Stator Unit 1 ETQ6DWGLE109 \ ETQ6DWGLN109

15 Dust Cover 1 ETQ6DWGLE110 \ ETQ6DWGLN110


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LIMITED WARRANTY

Eastern Tools & Equipment, Inc. will repair or replace, free of charge, any part or parts of the generator that aredefective in material or workmanship or both. Transportation charges on parts submitted for repair or replacement

under this Warranty must be borne by purchaser. This warranty is effective for the time period and subject to theconditions provided for in this policy. For warranty service, find the nearest Authorized Service Dealer by contacting

the place of purchase or Eastern Tools & Equipment, Inc. THERE IS NO OTHER EXPRESSED WARRANTY.IMPLIED WARRANTIES, INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A

PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM PURCHASE, OR TO THE EXTENTPERMITED BY LAW ANY AND ALL IMPLIED WARRANTIES ARE EXCLUDED. LIABILITY FORCONSEQUENTIAL DAMAGES UNDER ANY AND ALL WARRANTIES ARE EXCLUDED TO THE EXTENTEXCLUSION IS PERMITTED BY LAW. Some states do not allow limitations on how long an implied warranty lasts,

and some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitationand exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights,which vary from state to state.

Eastern Tools & Equipment, Inc.

WARRANTY PERIOD***WITHIN U.S.A AND CANADA OUTSIDE U.S.A. AND CANADA

ENGINES CONSUMER

USE

COMMERCIAL

USA

CONSUMER

USE

COMMERCIAL

USE

DIESELGENERATOR

1 yearor 1000 hours

1 yearor 1000 hours

1 yearor 1000 hours

1 yearor 1000 hours

About Your Product Warranty

Eastern Tools & Equipment, Inc. welcomes warranty repair and apologizes to you for being inconvenienced. AnyAuthorized Service Dealer may perform warranty repairs. Most warranty repairs are handled routinely, but sometimeswarranty service may be inappropriate. For example, warranty would not apply if an engine is damaged because of

misuse, lack of routine maintenance, shipping, handling, warehousing and improper installation. Similarly, warranty isvoid if the serial number on the engine has been removed or if the engine has been altered or modified. If a customerdiffers with the decision of the Service Dealer, an investigation will be made to determine whether the warrantyapplies. Ask the Service Dealer to submit all supporting facts to his Distributor or the factory for review. If the

distributor or the factory decides that the claim is justified, the customer will be fully reimbursed for those items thatare defective. To avoid misunderstanding, which might occur between the customer and the dealer, listed below aresome of the causes of engine failure that the warranty does not cover.

Normal wear:

Engines and generators, like all mechanical devices, need periodic parts service and replacement to perform well.Warranty will not cover repair when normal use has exhausted the life of a part of an engine.


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Improper maintenance:

The life of an engine or your equipment depends upon the conditions under which it operates, and the care it receives.Some applications, such as tillers, pumps, and rotary movers, are very often used in dusty or dirty conditions, whichcan cause what appears to be premature, wear. Such wear, when caused by dirt, dust, spark pug cleaning grit, or other

abrasive material that has entered the engine because of improper maintenance is not covered by warranty.


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List for comments from users

Date of

Manufacture

Name of user Model Number

Address of user Occupation

Place of purchase

Packaging conditions

Operating conditions

Parts Conditions

Malfunction problem

Opinions or suggestions

Note: Please mail the above card to: Eastern Tools & Equipment, Inc.

12220 Rivera Rd, Suite B

Whittier, CA 90606


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Appendix:

1. Attached list of tools, fittings, and subassemblies

Order No. Name Qty Remarks

1 Air-cooled diesel welder and generator set 12 Kit 1

3 Plastic cover 1

4 Plug and power supply 1

2. Attached technical documents

Order No. Name Qty Remarks

1 Air cooled diesel welder and generatormanual

1

2 Diesel engine instruction manual 1

3 Diesel engine parts listing 14 Certificate of Quality 1

5 Packing List 1


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EASTERN TOOLS & EQUIPMENT, INC.

TEL: 1-626-960-6299

FAX: 1-626-960-6244

WEB SITE.http://easterntools.com

Date post:	02-Jun-2018
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Generator Welder

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